Mattress and upholstering pad



Ma .rh26,1940. ,RUM F 2,194,569

MATTRESS AND UPHOLSTERING PAD Filed Oct. 22, 1937 INVENTOR. [RWJNC J EUMPF 3 TORNEY Patented Mar. .26, W40

UNITED TATES PATENT Irwin J. Rumpi', Burlingarne, Calii., assignor of one-half to Herman Rumpf, San Francisco,

Calif.

Application October 22, 1937, Serial No. 170,364

9' Claims.

My present invention relates to mattresses and like pads, and more particularly to a pad of flocculated fibrous material, such as hair secured together by an elastic adhesive and having reenforcing metallic springs arranged therein. 7

An object of my invention is to provide a new and novel form of mattress or pad of flocculated fibrous material having an elastic adhesive as a binding medium in which metallic springs are used in a novel manner to increase the resilience thereof.

Another object of the invention is to provide a mattress of rubberized hair having opposite sides of different resilience in which metallic springs of different stiffness are incorporated in a new and novel manner.

Another object of the invention is to provide a new and novel method of positioning a metal spring in a resilient pad composed of flocculated fibrous 'material adhesively secured together as a preformed unit.

Another object of my invention is to provide a new and novel form of mattress having a plurality of separable mattress forming units which can be secured together in reversed relation to each other to provide a mattress having different degrees of resilience throughout its length.

A further object of my invention is to provide a new and novel form of reenforcing spring in which a single length of spring wire is wound to provide two concentrically disposed series of spaced convolutions.

Other objects and advantages of my invention will be in part pointed out hereinafter and in part evident to those skilled in the art as the description thereof proceeds.

For a better understanding of the invention reference should be had to the accompanying drawing, wherein there is shown by way of illustration and not of limitation, preferred embodiments thereof.

In the drawing;

Figure 1 is a fragmentary perspective view of a mattress constructed in accordance with a preferred form of my invention, with portions cut away and in section to disclose the inner construction thereof,

Figure 2 is a fragmentary sectional view of a pad constructed in accordance with another embodiment of my invention,

Figure 3 is a sectional view of a pad suitable for an automobile or railway car seats, having reenforcing spring meansdisposed therein in accordance with my invention,

Figure 4 is a perspective view of one unit of a mattress constructed in accordance with another aspect of myinvention, with an enclosing cover thereover,

Figure 5 is a perspective view of a complete mattress showing. three of the units illustrated in Figure 4, disposed within a larger outer enclosing cover, and

Figure 6 is a perspective view of an improved form of spring which is particularly adapted for use with my invention. 10

In carrying out my invention, and particularly in the manufacture of mattresses, I prefer to use horsehair or other animal hair, but in some instances I may resort to the use of substitutes, such as for example, Algerian grass, coconut fibre and the like, md as an adhesive for securing the various fibres in a flocculated condition, I may use any flexible adhesive which will not dry out and become brittle with age. Examples of such adhesives i clude various rubber solutions, rubber latex, gut'ta-percha solutions and latex.

I am aware that in the past, pads have been constructed of various fibrous materials secured together by the use of various types of adhesives, and in which springs have also been incorporated in various manners, but insofar as I am aware, no one up to the present time has constructed a mattress or pad in the manner contemplated by my invention, wherein as will hereinafter appear, the fibres constituting the pad-like units 30 are arranged and combined with reenforcing springs in a new, novel and convenient manner.

As shown in Figure l of the drawing, the mattress contemplated by my present invention comprises two superimposed preformed pad-like units, the upper one being designated by the numeral l0, andthe lowerone being designated by the numeral, II. The pad H) is preferably composed of hair or fibres of relatively fine texture, which will produce a relatively soft resilient sur- 4 face, and the pad-like unit II is preferably constructed of relatively coarser hair or fibres, which will produce a somewhat less resilient surface. Between the upper and lower pads 10 and H, I int'erpose a fabric H, which 'is preferably of an open mesh character. However, when a rubber containing adhesive is used in forming the units of the mattress, this fabric l2 may be a sheet of rubberized cloth. Extending upwardly from the fabric [2 and into the body of the upper pad Hi, I provide a plurality of relatively light springs 13 that are disposed in spaced relation over the en tire area of the mattress, and extending downwardly from the fabric l2 and into the lower pad like unit H, I provide a plurality of relatively lid stifier springs M. These springs l3 and H are inserted into annular cavities formed by cylindrical cuts 95 and i6 made respectively in the pads l0 and ii that extend from the fabric I2 slightly more than half way through the respective pads. The springs i3 and H of the pads I0 and H are further arranged so that they will be positioned in staggered relation with respect to each other, and at their inner ends they engage the fabric H2 at a point between two springs at the other side thereof which extend into the opposite pad. With this arrangement the lighter springs l3 will serve to reenforce the upper and softer pad l0, and the relatively stiffer springs M will effectively serve to reenforce the less resilient pad-like unit H, and as a result, the resilient character of the upper and lower sides of the mattress will not be influenced by the character of the springs used in conjunction with the other side thereof.

In forming the pads HI and II, I may use a mold of the desired size into which the hair or fibres are arranged and compacted while wet with the elastic adhesive, or I may arrange the hair or fibres upon a large flat surface and form a size-' able layer from which units of a smaller size and shape can be cut. In this operation, as an important aspect of my invention, I comb or otherwise arrange the fibres or hair, so that they will lay in the main with their axes extending along horizontal lines, and as a result, the padding so formed will be much softer and free of the objectionable pricking efiect which might result if the hairs are, allowed to project transverse to the plane of the pads. After the hair or fibres are arranged in the above manner, I apply the adhesive to this fiocculent mass as a fine spray, applying sufiicient adhesiveto the individual fibres to cause them to adhere together, and as a later treatment I may, if desired, apply additional adhesive in the form of a spray to completely incase the fibres after the unit has taken a definite shape. The spring receiving cuts l5 and IS in the pad-like units In and II can now be formed by a tubular tool having its end sharpened to a knifelike edge, and while these cuts are shown in the drawing as having some width, it is to be understood'that when the tubular knife is withdrawn,

the cuts, due to the flexibility of the fibres, willsubstantially close over the convolutions of the springs l3 and I4 when they are placed therein. This cutting of the pad-like units can be carried out in a simple and convenient manner by mounting the tubular knifelike tool upon the spindle of a portablehand drill which will rotate the knife at a high speed about its central axis, and to prevent too deep a, cut in the pad-like units, this cutting tool may be provided with an adJus'table shoulder forming a stop, which will contact the surface of the pad when the out has progressed into the pad to the proper depth. Instead of using a single relatively stiff spring H with a single cut IS in the pad I I, I may, if desired, use a double spring having two concentrically arranged spiral portions. Such a spring is used in con- Junction with two concentric cuts such as are designated by the numeral I! in this figure of the drawing. A spring suitable for use in this latter arrangement is to be described hereinafter.

After the pad-like units In and II have been secured upon the fabric l2 with the springs l3 and erably formed of relatively coarse hair or fibres, and in which the general disposition ofthe hair or fibres extends in a vertical direction when the strip is in place. The purpose of this strip I! is to reenforoe the edges of the mattress and com:- pensate for the absence of springs [3 or ll 'at these points.

In Figure 2 of the drawing, there is shown a modified form of my invention, wherein the reenforcing springs are disposed in only one of two superimposed pad-like units. As here illustrated, the mattress or pad comprises an upper unit 20. constructed in a manner similar to that employed in forming the units it and H hereinbefore described, and having either single springs 2! or double springs 22 disposed in the spring receiving cylindrical cuts. In this arrangement the mattress or pad may be provided with single springs 2! throughout its inner area and with double springs 22 arranged around its borders, or the springs may all be of the same character. After the springs 2| or 22 are positioned within the pad-like unit 20 they are secured, in place by adhesively securing a fabric 23 thereover, and to the other side of this fabric there is adhesively applied a second pad-like unit 24, which will render the mattress or pad reversible, so that either side thereof may be used as the top surface. After thepad-like units 20 and 24 have been secured together in the above manner with the springs 2| or 22 therein, a groove 25 is formed around the outside edges thereof, and in this groove I adhesively secure a reenforcing band 26 of fiocculated and adhesively secured hair or other fibres in which the general arrangement of the hair or fibres is in a vertical direction; so that they will be subjected to endwise pressure and, as a result, provide a less resilient edging about the mattress or pad that will not'readily collapse and become deformed.

In Figure 3 of the drawing, there is shown an adaptation of my improved double spring arrangement as applied to a seat pad such as is suitable for automobile and railway car seats. In this arrangement the pad is preferably mounted over a frame 26 upon which the lower ends of a plurality of double convolution springs 21 are adapted to rest. These springs 21 may be secured upon a frame 26 or not, as desired. As here shown, the pad, unit, designated by the numeral 28, is preformed so as to have the contour of a seat, and cut into its under surface at spaced points and extending to different depths, it has concentrically arranged spring receiving cuts 29 into which the springs 21 are inserted. After being thus assembled the pad 28 may be covered with any desired upholstering fabric or leather 3|, the edges of the fabric or leather 3| being secured to the frame in any suitable manner.

In Figure 4 of the drawing, there is shown a single mattress forming unit incased in an enclosing slip cover 32 along one side of which there is provided a zipper type closure means 28, and in Figure 5 of the drawing, I have shown three such units as arranged side by side and enclosed within an additional slip cover 24 having zipper closure means 35 along one of its sides. When the mattress units are constructed in ac cordance with the arrangement illustrated in Figure 1 of the drawing, with its opposite side" of relatively different resilience, it will be possi ble by arranging a plurality of these mattress forming units side by side, in the manner illustrated in Figure 5, with different sides uppermost, to thus produce a mattress having different degrees of resilience throughout its length.

For example, the two end units may have their relatively less resilient sides uppermost, and the inner unit may have its more resilient side uppermost. As a. result, the completed mattress will be relatively more resilient and soft at its middle portion than at its ends, whereas if the complete mattress so assembled is turned completely over, the middle portion oi the mattress will be relatively less resilient than the end portions thereof.

In Figure 6 of the drawing, I have shown a form of double spring which is particularly applicable to the carrying out of my present invention. This spring is formed of a single continuous piece of spring wire 36 having outer convolutions 31 that terminate in a complete ring 38 at the top thereof. At the lower end of the outer convolutions 31 the wire 36 is brought inwardly after a complete turn and formed with upwardly extending inner convolutions 39 that terminate at an inner concentrically arranged ring 4|]. With such a spring it will be seen that.

since-the inner and outer convolutions are connected together at their lower ends they will tend to retain this position and not become displaced when they are inserted in the concentrically arranged spring receiving cuts described above.

-While I have, forthe sake of cleamess and in order to disclose my invention so that the same can be readily understood, described and illustrated specific devices and arrangements, I desire to have it understood that this invention is not limited to the specific means disclosed, but may be embodied in other ways that will suggest themselves to persons skilled in the art. It is believed that this invention is new and it is desired to claim it so that all such changes as come within the scope of the appended claims are to be considered as part of this invention.

Having thus described my invention, what I claim and desire to secure by Letters Patent is- 1. In a reversible mattress of the character described the combination of a unit composed of relatively fine fibres secured together in a flocculent condition by an impervious elastic binding material, a second similarly formed unit composed of relatively coarser fibres sec'ured together in a flocculent condition by an impervious elastic binding material, an open mesh fabric disposed between said two units and adhesively attached thereto, a plurality of relatively light springs extending from said fabric into said first unit at spaced points throughout its area, and a plurality of relatively stiffer springs extending in an opposite direction from said open mesh fabric and into said second unit, the light springs extending into said first unit being arranged in staggered relation with the relatively stiffer springs which extend into the second unit.

2. In a reversible mattress of the character described, the combination of a fiat pad-like unit composed of relatively fine hair secured together in a flocculent condition by an impervious elastic binding material, a second similarly formed padlike unit composed of relatively coarser hair secured together in a flocculent condition by an impervious elastic binding material, an open mesh fabric disposed between said two pad-like units and adhesively attached thereto, a plurality of relatively light springs extending from said fabric into said first unit at spaced points throughout its area, and a plurality of relatively stifier springs extending in an opposite direction from said open mesh fabric and into said second unit, the light springs extending into said first unit being arranged in staggered relation with the relatively stiffer springs which extend into the second pad-like unit.

3. In a reversible mattress of the character described, the combination ofa fiat preformed unit composed of relatively fine hair secured together in a flocculent condition by an impervious elastic binding material, a second similarly preformed unit composed of relatively coarser hair secured together in a flocculent condition by an impervious elastic binding material, a fabric disposed between said two units and adhesively attached thereto to form a single unitary structure, a plurality of relatively light springs extending from one side of said fabric into said first unit at spaced points throughout its area, a plurality of relatively stiffer springs extending in an opposite direction from the other side of said fabric and into said second preformed unit, the light springs extending into said first unit being arranged in staggered relation with the relatively stiffer springs which extend into said second unit, and a band-like unit of hair secured together by an adhesive disposed edgewise around said first and second units and over the edge of said fabric, the individual hairs of said latter unit being arranged in a substantially vertical direction when the mattress is completed, whereby the edges thereof will be of increased resilience.

4. In a mattress of the character described, the combination of a preformed unit of fibrous material secured together as a unit by an elastic adhesive, a second similar preformed unit of fibrous material secured together by an elastic adhesive, a fabric disposed between said first and second preformed units, and a plurality of springs arranged in staggered relation on opposite sides of said fabric and extending into said preformed units with their axis transverse to the planes thereof, said springs being cavities formed by cylindrical cuts extending from said fabric into the adjacent opposed sides of each of said preformed units.

5. In a mattress of the character described, the combination of a fibrous material secured together as a unit by an elastic adhesive, the fibres of said unit' being disposed in the main along horizontal lines, a second similar unit of flocculent fibrous material secured together by an elastic adhesive, a fabric disposed between and adhesively secured to the adjacent surfaces of said first and second preformed unit, a plurality of springs arranged in 1 staggered relation on opposite sides of said fabric and extending into said preformed units with their axis transverse to the plane thereof, said springs being disposed in cylindrical cuts extending from said fabric into the adJacent sides of each of said preformed units, said two units when preformed unit of fiocculated disposed in annular second similar unit of flocculatedhair secured together by an elastic adhesive with the individual hairs thereof disposed in a horizontal direction, a fabric disposed between and adhesively secured to said first and second preformed units, a plurality of springs arranged in staggered relation on opposite sides of said fabric and extending into said preformed units with their axis transverse to the planes thereof, said springs being disposed in cylindrical cuts extending from said fabric into the engaging sides of each of said preformed units, said two units when secured together upon said open mesh fabric having a dovetail groove formed completely therearound, and a preformed reenforcing strip of hair adhesively secured together with the individual hairs extending in the main in a vertical direction secured in said dovetail groove to thereby reenforce the edges of the mattress thus formed.

'7. In a mattress or pad of the character described, the combination of a preformed pad-like unit of adhesively secured fibrous material having spaced annular spring receiving cavities extending partially therethrough from one side thereof, said annular spring receiving cavities being formed by a single cylindrical cut made into the fibrous material of said pad-like unit, a helical spring having aligned convolutions disposed in each of said cavities, and means extending over the open ends of said cavities and adhesively secured to the surface of said pad-like unit for retaining the cut portions of said unit in coamaceo unit of rubberized hair having a plurality of groups of concentrically arranged cavities for the reception of springs, said cavities being formed by making concentric cylindrical cuts which extend into the pad-like unit from one side thereof,

a helical spring disposed in the cavities of each group with their convolutions concentric to each other, and means secured to the out side of said pad and over the ends of said springs for retaining the portions of the pad-like unit within said cylindrical cuts in a concentric position within said springs.

9. In a mattress or pad of thecharacter described, the combination of a preformed pad-like unit of fibrous material having a plurality of groups of concentrically arranged cavities for the reception of springs, said cavities being formed by making two concentric cylindrical cuts which extend into the pad-like unit from one side thereof, a double helical spring disposed in each group of cavities, said double helical spring having a series of inner and outer convolutions arranged concentric to each other and being connected together at one end, and means secured to the out side of said pad and over the connected ends of said springs for retaining the portions of said pad-like unit separated by said cylindrical cuts in a concentric position within said springs.

IRWIN J. RUMPF. 

